System for forming a sloped surface on a flat roof deck

Abstract

A system for the formation of a sloped roof surface on a pre-existing flat roof deck through the utilization of a mold assembly comprising a plurality of angularly configured beams spaced from one another and cooperatively interconnected with baffle plates and an overlying grill structure having a substantially open or pass-through construction to the extent that a confined space defined by the above set forth component is to be filled with a light-weight cementitious or other operable material preferably suitable for roofing, resulting in an inclined or sloped outer surface being formed contiguous with the grill structure such that the cured cementitious material and aforementioned components become a substantially integral, one-piece construction permanently secured to the pre-existing, original flat roof deck.

Now that the invention has been described, what is claimed is: 
     
       1. A system for forming a sloped roof surface on a flat roof deck, said system comprising: a. a plurality of beam structures each having an elongated configuration and disposed in spaced, substantially parallel relation to one another collectively along a length of the flat roof deck,   b. each of said beams secured to the roof deck along a bottom longitudinal side thereof and comprising a top longitudinal side angularly inclined from a first end to a second end thereof,   c. a plurality of baffle plates transversely interconnected between each-two adjacent beam structures and being disposed in spaced, parallel relation to one another along the length of said beam structures,   d. said plurality of baffle plates comprising successively greater transverse dimensions from said first to said second end of said beam structures,   e. said beam structures and said plurality of baffle plates cooperatively structured to define a confined space having an inclined opening extending between said first and said second ends of said plurality of beams, and   f. grill means for covering said confined space positionable at an incline substantially equal to the incline of said plurality of beam structures and said inclined opening and in overlying, substantially covering relation to said baffle plates and said confined space in spaced-relation to the flat-roof deck and including an open, pass through construction for directing a moldabe roofing material therethrough into said confined space.   
     
     
       2. A system as in claim 1 wherein said grill means comprises at least one grill structure having a bordering frame disposed about a periphery thereof and a plurality of brace members connected to said frame and disposed in spaced-relation to one another a distance sufficient to allow passage therethrough of the moldable material. 
     
     
       3. A system as in claim 2 wherein said plurality of brace members comprise a plurality of slats disposed in spaced, parallel relation to one another and connected between oppositely disposed portions of said frame and in transverse orientation relative to the length of said beam structures. 
     
     
       4. A system as in claim 3 wherein said plurality of slats are disposed at an angular orientation of less than 90 degrees relative to the length of said one grill structure. 
     
     
       5. A system as in claim 1 wherein said grill means comprises a plurality of grill structures each comprising a bordering frame disposed about a periphery thereof and a plurality of brace members connected to said frame and disposed in spaced-relation to one another a distance sufficient to allow passage therethrough of the moldable material and dimensioned to fit between adjacent ones of said beam structures, said plurality of grill structures sufficient in number to substantially cover said inclined opening in overlying relation to said confined space. 
     
     
       6. A system as in claim 5 wherein said plurality of brace members of each grill structure comprises a plurality of slats disposed in spaced, parallel relation to one another and connected between oppositely disposed portions of said frame and in transverse orientation relative to the length of said beam structures. 
     
     
       7. system as in claim 6 wherein said plurality of slats are disposed at an angular orientation of less than 90 degrees relative to the length of said one grill structure. 
     
     
       8. A system as in claim 7 wherein each of said plurality of baffle plates are dimensioned to include an upper longitudinal edge spaced an equal distance inwardly from said top longitudinal side of adjacent ones of said beam structures. 
     
     
       9. A system as in claim 8 wherein each of said plurality of grill structures are transversely dimensioned to be disposed between adjacent ones of said plurality of beam structures in supported engagement on said upper longitudinal edges of said baffle plates. 
     
     
       10. A system as in claim 1 wherein said confined space comprises a plurality of open compartments defined by cooperatively positioned interconnected baffle plates and beam structures, said compartments comprising progressively greater volumes extending from said first end to said second end of said plurality of beams. 
     
     
       11. A system as in claim 10 wherein each of said compartments are disposed and structured to be filled with the roofing material to a level contiguous to said grill means, whereby a sloped outer roof surface is defined contiguous with said grill means. 
     
     
       12. A system as in claim 1 wherein each of said beam structures comprises an attachment plate secured to said lower longitudinal side and extending transversely outward therefrom, said attachment plate of each beam structure fixedly securable to said roof deck. 
     
     
       13. A system as in claim 1 wherein each of said beam structures comprises a plurality of elongated channels formed on at least one side face thereof, each of said channels dimensioned to receive and retain a correspondingly positioned longitudinal end of one of said plurality of baffle plates. 
     
     
       14. A system as in claim 13 wherein cooperatively positioned ones of said plurality of channels on adjacent ones of said beam structures are disposed in co-planar relation to one another and co-planar pairs of said channels are disposed to receive opposite ends of a common baffle plate. 
     
     
       15. A system as in claim 1 wherein at least one of said beam structures is an end most beam structure and a plurality of secondary baffle plates are secured transversely to an outer surface thereof, each of said secondary baffle plates having a proportionally greater transverse dimension from said first end towards the second end and each including an angularly declining upper longitudinal side extending from said end-most beam structure to an outer distal end of said respective secondary baffle plate which defines said second end thereof. 
     
     
       16. A system as in claim 1 further comprising tie-end means for forming a sloped roof extension between a gabled roof surface and one longitudinal end of assembled ones of said beams and baffle plates; said tie-end means including a plurality of parallel beam extensions secured to a correspondingly positioned end-most baffle plate and extending outwardly therefrom into engagement with a sloped gabled roof surface; a plurality of grill structures secured to an upper portion of adjacent ones of said beam extensions in overlying relation to a confined space therebetween and including an open, pass-through construction for directing a moldable roofing material therethrough into said confined space. 
     
     
       17. A system as in claim 16 wherein said auxiliary grill structures and said beam extensions are cooperatively disposed and configured to define a sloped disposition between the gabled roof surface and said one longitudinal end of said assembled ones of said beams and baffle plates.